Air-conditioning apparatus and method of manufacturing air-conditioning apparatus

ABSTRACT

An air-conditioning apparatus includes: a compressor, a first heat exchanger, an expansion unit and a second heat exchanger that are connected, by a pipe, in a refrigerant circuit through which refrigerant flows, wherein the first heat exchanger includes: a radiator fin, multiple tubes extending through the radiator fin and through which the refrigerant flows, and a side plate provided at end portions of the multiple tubes, and having multiple holes formed thereon, through which the multiple tubes are extended, wherein, on the side plate, between the holes corresponding to the multiple tubes to be connected, a marking corresponding to a type of a connection member that connects the multiple tubes is provided.

TECHNICAL FIELD

The present invention relates to an air-conditioning apparatus includinga heat exchanger provided with side plates and a method of manufacturingthe air-conditioning apparatus.

BACKGROUND ART

A heat exchanger employed in an air-conditioning apparatus is configuredwith, for example, a radiator fin, a tube and a side plate. There areprovided multiple radiator fins and tubes, and the multiple tubes areinserted into the multiple radiator fins. The side plate is provided atend portions of the tubes, and the side plate has multiple holes formedthereon through which the multiple tubes are inserted. In the heatexchanger, connection members that connect the multiple tubes areprovided on the side plate. As the connection member, for example, aU-bent tube, a three-way bent tube, a bulge three-way tube and othertubes can be provided. Moreover, when the tube is a hairpin tube, thetube and the connection member are integrally formed.

The connection member provided to such a heat exchanger has variouskinds of connection patterns (path patterns) that are complex.Therefore, a drawing on which a path pattern is provided is separatelyprepared. Then, a worker who manufactures the heat exchanger attachesparts to assemble the heat exchanger while alternately comparing theheat exchanger and the drawing providing the path pattern. When thenumber of parts related to the path pattern is large, it exceeds 100 pera single heat exchanger. Moreover, the parts include several types insome cases. Consequently, there is a possibility that the working hoursare increased and a failure caused by an attachment mistake occurs.

Moreover, as described above, the parts related to the path pattern aremainly four types: the hairpin tube; the U-bent tube; the three-way benttube; and the bulge three-way tube. In these connection members, thereis no limitation to functions, an outer shape, attachment number andplace, and so forth. Therefore, there is a possibility of increase inworking hours due to inadequate confirmation of attachment places andinadequate confirmation of the connection member itself, and occurrenceof failure caused by attachment mistake due to inadequate confirmationof attachment places and inadequate confirmation of the connectionmember itself.

Note that, when these connection members are attached by brazing, it isdifficult to detach the members that have been attached once. Therefore,when an attachment mistake occurs, the whole heat exchanger includingthe radiator fins and the side plates has to be discarded.

Here, in Patent Literature 1, there is disclosed a method ofmanufacturing a heat exchanger including multiple bent tubes. In PatentLiterature 1, a heat exchanger is manufactured by attaching multiplebent tubes in advance to a support material having holes for insertingthe bent tubes formed thereon, and fitting the support material to atube inserted into a plate fin. In this manner, Patent Literature 1employs the support material to eliminate the confirmation of attachmentplaces of the bent tubes, thereby, intends to improve workability inassembly of the heat exchanger.

CITATION LIST Patent Literature

-   Patent Literature 1: Japanese Unexamined Patent Application    Publication No. 2009-68805

SUMMARY OF INVENTION Technical Problem

However, since the heat exchanger disclosed in Patent Literature 1requires the support material, manufacturing costs are increased.Moreover, in Patent Literature 1, attachment of bent tubes only isdisclosed, and attachment workability when there are multiple connectionmembers is not at all considered.

The present invention has been made in view of the above circumstances,and provides an air-conditioning apparatus and a method of manufacturingthe air-conditioning apparatus that reduce manufacturing costs andimprove attachment workability even when there are multiple connectionmembers.

Solution to Problem

An air-conditioning apparatus of an embodiment of the present inventionincludes: a compressor, a first heat exchanger, an expansion unit and asecond heat exchanger that are connected, by a pipe, in a refrigerantcircuit through which refrigerant flows, wherein the first heatexchanger includes: a radiator fin, a plurality of tubes extendingthrough the radiator fin and through which the refrigerant flows, and aside plate provided at end portions of the tubes, and having a pluralityof holes formed thereon through which the tubes are extended, wherein,on the side plate, between the holes corresponding to the tubes to beconnected, a marking corresponding to a type of a connection member thatconnects the tubes is provided.

Advantageous Effects of Invention

According to the present invention, on the side plate, between the holescorresponding to the multiple tubes to be connected, markingscorresponding to the types of the connection members that connect themultiple tubes is provided. Therefore, positioning is performed withease without any support material. Consequently, the manufacturing costsis reduced. Moreover, the markings are different by respective types ofthe connection members, and thereby the connection member to be attachedis recognized with ease. Therefore, the attachment workability isimproved even when there are multiple connection members.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a circuit diagram showing an air-conditioning apparatus 1according to Embodiment 1 of the present invention.

FIG. 2A is a side view showing a first heat exchanger 4 in Embodiment 1of the present invention.

FIG. 2B is a front view showing the first heat exchanger 4 in Embodiment1 of the present invention.

FIG. 3 is a front view showing a side plate 13 of the first heatexchanger 4 in Embodiment 1 of the present invention.

FIG. 4 is a diagram showing types of markings 15 in Embodiment 1 of thepresent invention.

FIG. 5 is a flowchart showing a method of manufacturing theair-conditioning apparatus 1 according to Embodiment 1 of the presentinvention.

FIG. 6 is a front view showing the side plate 13 of the first heatexchanger 4 in Embodiment 1 of the present invention.

DESCRIPTION OF EMBODIMENTS

Hereinafter, an embodiment of an air-conditioning apparatus 1 and amethod of manufacturing the air-conditioning apparatus 1 according tothe present invention will be described with reference to drawings. Notethat the embodiment to be described below does not limit the presentinvention. Moreover, including FIG. 1, relations between sizes ofrespective components in the following drawings are different from thosein actuality in some cases.

Embodiment 1

FIG. 1 is a circuit diagram showing an air-conditioning apparatus 1according to Embodiment 1 of the present invention. The air-conditioningapparatus 1 will be described based on FIG. 1. As shown in FIG. 1, theair-conditioning apparatus 1 includes a refrigerant circuit 2. In therefrigerant circuit 2, a compressor 3, a first heat exchanger 4, anexpansion unit 5 and a second heat exchanger 6 are connected by a pipe 7to allow a flow of refrigerant.

The compressor 3 compresses the refrigerant. The first heat exchanger 4is provided, for example, outdoor, and exchanges heat between outdoorair and the refrigerant. The first heat exchanger 4 is provided with aninflow header 4 a on an inflow side of the refrigerant, and the inflowheader 4 a distributes the refrigerant discharged from the compressor 3to each of tubes 12 of the first heat exchanger 4. Moreover, the firstheat exchanger 4 is provided with a first outflow header 4 b on anoutflow side of the refrigerant, and the first outflow header 4 bcollects the refrigerant flowing out of each tube 12 to allow therefrigerant to flow out to the expansion unit 5.

The expansion unit 5 expands the refrigerant and reduces the pressure ofthe refrigerant. The second heat exchanger 6 is provided, for example,indoor, and exchanges heat between indoor air and the refrigerant. Thesecond heat exchanger 6 is provided with a distributor 6 a on an inflowside of the refrigerant, and the distributor 6 a distributes therefrigerant flowing out of the expansion unit 5 to each of tubes 12 ofthe second heat exchanger 6. Moreover, the second heat exchanger 6 isprovided with a second outflow header 6 b on an outflow side of therefrigerant, and the second outflow header 6 b collects the refrigerantflowing out of each tube 12 to allow the refrigerant to flow out to thecompressor 3.

FIG. 2A is a side view showing the first heat exchanger 4 in Embodiment1 of the present invention, and FIG. 2B is a front view showing thefirst heat exchanger 4 in Embodiment 1 of the present invention. Next,the first heat exchanger 4 will be described. As shown in FIG. 2A andFIG. 2B, the first heat exchanger 4 includes a radiator fin 11, multipletubes 12 and side plates 13. For example, multiple radiator fins 11 areprovided and the multiple radiator fins 11 are disposed at intervalsmutually. The outdoor air flows through the multiple radiator fins 11.

The multiple tubes 12 are inserted through the radiator fins 11 andallows the refrigerant to flow therethrough.

The side plate 13 is provided at end portions of the tubes 12, and hasmultiple holes 13 a formed thereon through which the multiple tubes 12are inserted. The side plates 13 are provided, for example, at both endportions of the tubes 12 to sandwich the radiator fins 11. An upper endportion and a lower end portion of the side plate 13 are bent 90 degreesin the direction opposite to the radiator fins 11.

FIG. 3 is a front view showing the side plate 13 of the first heatexchanger 4 in Embodiment 1 of the present invention. Next, the sideplate 13 of the first heat exchanger 4 will be described. As shown inFIG. 3, on the side plate 13, between the holes 13 a corresponding tothe multiple tubes 12 to be connected, markings 15 corresponding to thetypes of the connection members 14 that connect the multiple tubes 12are provided.

As the connection member 14, for example, a U-bent tube 14A in a Ushape, a three-way bent tube 14 b in a T shape, a bulge three-way tube14 c in a non-T shape, and other tubes can be provided. Moreover, inEmbodiment 1, the tube 12 is a hairpin tube, and the tube 12 and theconnection member 14 are integrally formed.

FIG. 4 is a diagram showing types of the markings 15 in Embodiment 1 ofthe present invention. As shown in FIG. 4, in the case of the hairpintube, the marking 15 is a single straight line. In the case of theU-bent tube 14A, the marking 15 is two parallel straight lines. In thecase of the three-way bent tube 14 b, the marking 15 is two straightlines that are orthogonally crossed. In the case of the bulge three-waytube 14 c, the marking 15 is two straight lines that are crossednon-orthogonally, and an attachment direction is also indicated. Notethat the sizes of the markings 15 are appropriately determined.

In Embodiment 1, the markings 15 are provided by a marking jig, and themarking jig is made of metal. On the marking jig, a shape correspondingto the type of the marking 15 is formed. Note that the marking 15 may beprovided by a writing material, or may be provided by a sticker.Further, the marking 15 may be provided to cover the multiple holes 13a.

FIG. 5 is a flowchart showing a method of manufacturing theair-conditioning apparatus 1 according to Embodiment 1 of the presentinvention. Next, the method of manufacturing the air-conditioningapparatus 1 will be described. First, on the side plate 13, the multipleholes 13 a, through which the multiple tubes 12 are inserted, areformed. Specifically, on a metal plate in a flat-plate shape to serve asthe side plate 13 of the first heat exchanger 4, the multiple holes 13 aare formed by, for example, burring processing (step ST1).

Next, on the side plate 13, the markings 15 corresponding to the type ofthe connection member 14 that connects the multiple tubes 12 areprovided between the holes 13 a corresponding to the multiple tubes 12to be connected. Specifically, between the multiple holes 13 a, themarkings 15 are inscribed by a marking jig (step ST2). Then, the upperend portion and the lower end portion of the metal plate are bent 90degrees. Accordingly, the side plate 13 of the first heat exchanger 4 ismanufactured (step ST3). Thereafter, the first heat exchanger 4 ismanufactured by employing the side plates 13, and the air-conditioningapparatus 1 is manufactured by incorporating the first heat exchanger 4thereinto.

Next, an operation state of the air-conditioning apparatus 1 accordingto Embodiment 1 will be described. The compressor 3 sucks therefrigerant and compresses the refrigerant to discharge the refrigerantin a gas state of high temperature and high pressure. The dischargedrefrigerant flows into the first heat exchanger 4, and the first heatexchanger 4 condenses the refrigerant by heat exchange with the outdoorair. The condensed refrigerant flows into the expansion unit 5, and theexpansion unit 5 expands the condensed refrigerant and reduces thepressure thereof. Then, the refrigerant reduced in pressure flows intothe second heat exchanger 6, and the second heat exchanger 6 evaporatesthe refrigerant by heat exchange with the indoor air. At this time, theindoor air is cooled, and thereby cooling of the indoor space isperformed. Then, the refrigerant evaporated and brought into a gas stateof high temperature and low pressure is sucked by the compressor 3.

The air-conditioning apparatus 1 according to Embodiment 1 is used inperforming the cooling operation in this manner; however, theair-conditioning apparatus 1 may be configured to make it possible toperform, not only the cooling operation, but also the heating operationby providing a flow switching unit in the refrigerant circuit 2.

FIG. 6 is a front view showing the side plate 13 of the first heatexchanger 4 in Embodiment 1 of the present invention. Next, action ofthe air-conditioning apparatus 1 according to Embodiment 1 will bedescribed. In FIG. 6, solid-line arrows indicate attachment positions ofthe connection members 14 that are attached to the side plate 13 on oneend portion of the first heat exchanger 4 and flow directions of therefrigerant. Further, in FIG. 6, broken lines indicate attachmentpositions of the connection members 14 that are attached to the sideplate 13 on the other end portion of the first heat exchanger 4. In thismanner, in the first heat exchanger 4, since the connection members 14attached to the side plates 13 on both end portions are different,different markings 15 are provided to the side plate 13 on each of theboth end portions.

As shown in FIG. 6, each connection member 14 is attached in accordancewith the types of the markings 15. For example, at the portion where themarking 15 of two parallel straight lines is provided, the U-bent tube14A is attached. Meanwhile, at the portion where the marking 15 of twostraight lines that are orthogonally crossed is provided, the three-waybent tube 14 b is attached. Further, on the broken line, although themarking 15 is not shown, the hairpin tube (the tube 12) is attached.Then, the refrigerant flowing in from the inflow header 4 a flowsthrough the hairpin tube (the tube 12), the U-bent tube 14A, the hairpintube (the tube 12), and the three-way bent tube 14 b in this order.

One of the refrigerant branched at the three-way bent tube 14 b flowsthrough the hairpin tube (the tube 12), the U-bent tube 14A, the hairpintube (the tube 12), the U-bent tube 14A and the hairpin tube (the tube12) in this order, and flows out to the first outflow header 4 b.Meanwhile, the other one of the refrigerant branched at the three-waybent tube 14 b flows through the hairpin tube (the tube 12), the U-benttube 14A, the hairpin tube (the tube 12), the U-bent tube 14A and thehairpin tube (the tube 12) in this order, and flows out to the firstoutflow header 4 b.

As described above, on the side plate 13, between the holes 13 acorresponding to the multiple tubes 12 to be connected, markings 15corresponding to the types of the connection members 14 that connect themultiple tubes 12 are provided. Therefore, positioning is performed withease without any support material. Consequently, the manufacturing costsare reduced. Further, the markings 15 are different by respective typesof the connection members 14, and thereby the connection members 14 tobe attached are recognized with ease. Therefore, the attachmentworkability is improved even when there are multiple connection members14.

Moreover, this configuration reduces time for attaching the connectionmembers 14 to the first heat exchanger 4. Moreover, since the attachmentworkability is improved, quality of the first heat exchanger 4 isimproved. Further, even when the connection member 14 is attached bybrazing, since occurrence of attachment mistake is suppressed, the riskof discarding the whole first heat exchanger 4 including the radiatorfins 11 and the side plates 13 is reduced. This contributes to energysaving.

Note that, in Embodiment 1, the markings 15 are provided on the sideplates 13 of the first heat exchanger 4, however, the markings 15 may beprovided on the side plates 13 of the second heat exchanger 6. In thiscase, the refrigerant flowing in from the expansion unit 5 flows throughthe hairpin tube, the U-bent tube 14A, the three-way bent tube 14 b andothers, to flow out to the second outflow header 6 b. Further, inEmbodiment 1, the markings 15 are provided on the side plates 13 of thefirst heat exchanger 4, however, the markings 15 may be provided on theside plates 13 of the second heat exchanger 6.

Further, the tube 12 is a hairpin tube, and the tube 12 and theconnection member 14 are integrally formed. This configuration improvesattachment workability of the hairpin tube.

Even further, as the connection member 14, the U-bent tube 14A in the Ushape is used. This configuration improves attachment workability of theU-bent tube 14A.

Still further, as the connection member 14, the three-way bent tube 14 bin the T shape is used. This configuration improves attachmentworkability of the three-way bent tube 14 b.

Then, as the connection member 14, the bulge three-way tube 14 c in anon-T shape is used, and the marking 15 indicating the attachmentdirection of the connection member 14 is provided on the side plate 13.This configuration improves attachment workability of the bulgethree-way tube 14 c, and the attachment direction thereof is recognizedwith ease.

Further, on the side plate 13, the markings 15 are provided by themarking jigs. This improves workability in providing the markings 15.

Even further, on the side plate 13, the markings 15 are provided by thewriting material. This improves workability in providing the markings15.

Still further, on the side plate 13, the markings 15 are provided by thestickers. This improves workability in providing the markings 15.

Then, on the side plate 13, the marking 15 is provided to cover themultiple holes 13 a. This improves workability in providing the marking15.

Moreover, in a method of manufacturing an air-conditioning apparatus 1having a refrigerant circuit 2 through which refrigerant flows, therefrigerant circuit 2 including a compressor 3, a first heat exchanger4, an expansion unit 5 and a second heat exchanger 6 that are connectedby a pipe 7, the first heat exchanger 4 including a radiator fin 11,multiple tubes 12 that are inserted through the radiator fin 11 andallows the refrigerant to flow therethrough, and a side plate 13 that isprovided at end portions of the multiple tubes 12, the method includes:a step of forming multiple holes 13 a, through which the multiple tubes12 are inserted, on the side plate 13; and a step of providing, on theside plate 13, between the holes 13 a corresponding to the multipletubes 12 to be connected, a marking 15 corresponding to a type of aconnection member 14 connecting the multiple tubes 12. Therefore,positioning is performed with ease without any support material.Consequently, manufacturing costs are reduced. Moreover, the markings 15are different by respective types of the connection members 14, andthereby the connection members 14 to be attached are recognized withease. Therefore, the attachment workability is improved even when thereare multiple connection members 14.

REFERENCE SIGNS LIST

-   -   1 air-conditioning apparatus    -   2 refrigerant circuit    -   3 compressor    -   4 first heat exchanger    -   4 a inflow header    -   4 b first outflow header 5 expansion unit    -   6 second heat exchanger    -   6 a distributor    -   6 b second outflow header    -   7 pipe    -   11 radiator fin    -   12 tube    -   13 side plate    -   13 a hole    -   14 connection member    -   14 a U-bent tube    -   14 b three-way bent tube    -   14 c bulge three-way tube    -   15 marking

1. An air-conditioning apparatus comprising: a compressor, a first heatexchanger, an expansion unit and a second heat exchanger connected, by apipe, in a refrigerant circuit through which refrigerant flows, thefirst heat exchanger including a radiator fin, a plurality of tubesextending through the radiator fin and through which the refrigerantflows, and a side plate provided at end portions of the plurality oftubes, and having a plurality of holes formed thereon, through which theplurality of tubes are extended, on the side plate, between the holescorresponding to the plurality of tubes to be connected, a markingcorresponding to a type of a connection member connecting the pluralityof tubes being provided.
 2. The air-conditioning apparatus of claim 1,wherein the plurality of tubes include a hairpin tube, and the pluralityof tubes and the connection member are integrally formed.
 3. Theair-conditioning apparatus of claim 1, wherein, as the connectionmember, a U-bent tube having a U shape is employed.
 4. Theair-conditioning apparatus of claim 1, wherein, as the connectionmember, a three-way bent tube having a T shape is employed.
 5. Theair-conditioning apparatus of claim 1, wherein, as the connectionmember, a bulge three-way tube having a non-T shape is employed, and amarking indicating an attachment direction of the connection member isprovided on the side plate.
 6. The air-conditioning apparatus of claim1, wherein, on the side plate, the marking is provided by a marking jig.7. The air-conditioning apparatus of claim 1, wherein, on the sideplate, the marking is provided by a writing material.
 8. Theair-conditioning apparatus of claim 1, wherein, on the side plate, themarking is provided by a sticker.
 9. (canceled)
 10. A method ofmanufacturing an air-conditioning apparatus including a compressor, afirst heat exchanger, an expansion unit and a second heat exchangerconnected, by a pipe, in a refrigerant circuit through which refrigerantflows, the first heat exchanger including a radiator fin, a plurality oftubes extending through the radiator fin and through which therefrigerant flows, and a side plate provided at end portions of theplurality of tubes, the method comprising: forming a plurality of holes,through which the plurality of tubes are inserted, on the side plate;and providing, on the side plate, between the holes corresponding to theplurality of tubes to be connected, a marking corresponding to a type ofa connection member connecting the plurality of tubes.